Flush door



Dec. 11, 1928.

F. VICTOR FLUSH DOOR 3 Sheets-Sheet l Filed March 26, 1928 l l l l l l lI l l Dec 11, 192s. y 1,694,522

' F. VICTOR FLUSH DOOR Filed March 26, 1928 3 Sheets-Sheet 2 Ff'Qn/rfor' gnwntoz Mnesses y t5 :311% m (l f q futon/w11 F. VICTOR FLUSH DOORDec. 1l, 1928.

3 Sheets-Sheet Filed] March 26, 1928 A Fran/r l//'or afm Patented Dec.1l, 1928.

FRANK VICTOR, OF RIDGWAY, PENNSYLVANIA.

FLUSH DOOR.

Application filed March 26, 1928.

This invention relates to improvements in doors and more particularly todoors of the flush type. Doors of this type, as previously constructed,have presented various disadvantages. Some doors of this type have beenmade with a solid core with the result that they are expensive tomanufacture due to the amount of material required, are undesirablyheavy, and, are liable to warp under changes in weather conditions. Thepresent invention therefore has as one of its objects to provide a doorof the flush type which, while exceptionally substantial and durable andhaving a desired massive appearance, will, at the same time, becomparatively light in Weight, inexpensive to manufacture, not subjectto warping, and sound-proof.

Briefly described, the door, embodying the invention, comprises a framestructure which constitutes the body of the door and which consists ofan inner or core frame and an outer or edging frame, iii-combinationwith panels which constitute the faces of the door and which areassembled with and permanently secured to the said body frames, and theinvention has as a further object to so construct the frames comprisingthe body of the door that the component members of the frames may bereadily assembled and will embody interlocking parts of an extremelysimple nature which may be readily formed and interfitted so as toprevent any relative displacement of the component parts of the core andedging frames when assembled, the invention liliewise contemplating, inthis connection7 the formation and construction of the interlockingparts of the frame members so that not only will members of each framebe mutually locked together, but likewise the members of the two frameswill be mutually locked together, so that the door, as a whole. will beexceptionally substantial and there `will be no tendency towardseparation of any of its component parts either due to slamming` of thedoor or to expansion and contraction or changes in weather conditions.

Another object of the invention is to so construct the body framestructure of the door and the panels ot the door that a firm,substantial and yet simple interlocking of the panels and frame may beeffected thereby providing against any likelihood of sepa- Serial No.264,903.

ration of the panels from the frame and also providing against anydistortion of the panels due to warping.

Another object of the invention is to provide a door of the flush type,which while substantial and durable, may have the major areas of itspanels spaced with respect to each other lto provide dead air spaceswithin the door to render the same substantially sound-proof.

.While the accompanying drawings and the description which is to follow,constitute a disclosure of the preferred embodiment of the invention, itwill be understood the various changes may be made within the scope ofwhat is claimed.

In the accompanying drawings:

Figure l is a view in elevation of a door constructed in accordance withthe present invention, a portion of the panel at the near side of thedoor being broken away to illustrate a portion of the body framestructure in elevation:

Figure 2 is an edge elevation of the door;

Figure 3 is a topplan view of the door,

Figure 4 is a detail vertical sectional view taken substantially on theline Lt-4 of Figure l;

Figure 5 is a horizontal sectional view taken substantially on the lineof Figure l;

Figure 6 is a fragmentary, sectional, group perspective viewillustrating the body frame members of the door and one of the panels`mutually separated;

Figure 7 is a view partly in elevation and partly in vertical sectionillustrating one lower corner of the body frame structure of the door,one of the stiles of the edging .frame being omitted for the sake ofclearness;

Figure 8 is a view in side elevation of the structure shown in Figure 7;

Figure 9 is a vertical transverse sectional view taken substantially onthe line 9--9 of Figure 7 looking in the direction indicated by thearrows;

Figure l() is a plan view of the structure shown in Figure 7;

Figure ll is a fragmentary sectional perspective view of one lowercorner of the body frame structure of the door, the parts beingassembled and interloclred;

Figure l2 is a horizontal sectional view taken substantially on the linelQ-l of Figure il looking in the direction indicated by the arrows;

Figure 13 is a detail horizontal sectional view taken substantially onthe line 13-13 ot Figure l looking in the direction indicated by thearrows;

Figure lst is a fragmentary sectional perspective view of one lowercorner of the door structure as a whole, parts being broken away andsome parts omitted.

rl`he door, embodying the invention, comprises a body frame structureincluding` a core frame and an edging frame, in combination with panels,and in the drawings thecore frame is indicated in general by the numerall, the edging frame by the numeral Ely and the panels by the numeral 3.rl'he core frame l comprises stiles Ll, top and bottom rails 5, andintermediate rails G all oi these rails being preferably of the samecross sectional dimensions and each being lorined in its oppositelongitudinal edges with longitudinally medially extending dovetailgrooves, the grooves in the inner edges of the stiles el being indicatedby the numeral and those in the outer edges ot the stiles by the numeral8, and the grooves in the upper and lower edges of the top and bottomrails 5 being indicated by the numoral 9. These particularly referred togrooves in the stiles and rails ot the core frame serve a usefulpurpose, in the strue ture, as will presently be made clear. and whilethe lower and upper edges of the top and bottom rails 5 are formed withsimilar grooves as are also the upper and lower edges of theintermediate rails 6, these grooves serve no useful purpose and aremerely present due to trie fact that all of the members of the ira-.meare, stated.y of 'the same cross sectional dimensions and eon tour andtherefore may all be eut trom the same stock, thus ellecting a greatsaving in material well as labor incident to the production of theseveral trame members. By ,ference to Figures (i, l2 and i3 of the d1wings, it will be observedthat the ends o1 the rails 5 and 8 are formedwith tenons l0 which lit into the grooves 7 in the ini' edges of theStiles "i ot the core frame as tliese tenons are ot dovetail form,engagement or the same. in the dovetail grooves "27 serves to provide aninterlocking connection between the members of the said core frame, thisframe, when set up, being of rectangular form.

The edging frame likewise comprises stiles which are indicated by thenumeral il top and bottom rails indicated by the numeral l2, and byreference to Figures il. 5, l, il. i2, and 13, it will be observed thateach stile ll is formed upon its inner 'lare or edf/e with alongitudinally extending rib 13, these ribs being slidably fitted intothe grooves 8 ol' the stiles l ol the door frame as shown in liligures5, ll, l2 and lf3 whereby the stiles ot the edging 'frame areinterlocked throughout their length with the Correspondingv stiles otthe core frame. For a purpose to be presently explaineth each stile llis further 'formed in its inner lace at opposite sides of the dovetailrib lil, with a relatively narrow and deep groove let, these groovesextendingV parallel with respebt to the rib lil and likewise parallel tothe vertical side edges of the respective stile and relatively close tosaid side edges. ln a like manner, the top and bottom rails of theedgingl irame are similarly formed, these rails being provided upontheir under and upper faces, respectivelyU each with a longitudinallyextending dovetail rib l5 and these ribs litted at their ends intodovetail grooves lG which are formed at the upper and lower ends ol thestiles l of the core frame7 the said dovetail ribs l5 iitting in thedovetail grooves 9 in the up per and lower sides ol' the top and bottomrails 5 of the core frame, it beingv understood at this point that afterthe members ol the core frame have been assembled and interlocked` therails l2 oi' the edging trame are assembled with the core traine bybeing slid into the interlockingY engagement therewith which isei'lected by the litting of the said ribs l5 in the grooves 9 and i6. lnthis manner the top Vand bottom rails l2 of the edging frame areinterlocked with the corresponding rails as well as the stiles oii thecore frame. V3y reference to Figure T. it will be observed at thispoint, that the endsl of the top and bottom rails 5 ol the core frameabut against the inner edges of the stiles el ot said frame at the upperand lower ends thereof and it, will likewise be observed by reference toFigure T that the ends ot the ribs l5 upon the. top and bottom rails` ofthe edging frame terminate `flush with the inner walls the dovetailgrooves E which, as previously stated. are formed in the outer edges otthe said stiles el oi' the core. frame. As shown in Figure of thedrawings, each rail l2 of the edgingtrame. is termed at each end with avertically disposed dovetail groove 17 and it will be observed byreference to Figure 3 of the drawings that the ends olE the. dovetailribs 13 upon the inner faces ot the stiles ll of the edging frame lit inthese grooves thus providing an interlocking engagement between therails and stiles. As illustrated in Figures 85 G, 7, 8 and il of thedrawings the top and bottom rails l2 of the edging frame are. formed intheir upper and under sides with longitudinally extending` relativelynarrow and deep grooves 'i8 which are parallel to the ribs l5 oli therespect-ive rails and to the outer edges thereot` and which are locatedrelatively close to the said outer edges, these grooves corresponding tothe grooves 14 formed in the stiles!y 1'1 of the said edging frame andmatching at their ends with the respective ends of respective ones ofthe grooves in the stiles. It will also be observed by reference toFigures (5, 8 and 14 of the drawings that each rail 12 of the edgingframe is formed at each end, in a vertical plane with a respective oneof the grooves 18, with a tongue 19 which is of a thickness equal to thewidth of the respective groove.' The purpose of these tongues willpresently be explained.

From the description of the invention, thus far given, and by referenceto the drawings, it will now be evident that when the component membersof the core frame are aS- sembled by sliding the dovetail tenons 10,upon the top and bottom rails 5 0f said frame, into the upper and lowerends of the dovetail grooves 7 in the stiles 4, the rails and stileswill be interlocked so that there can be no lateral separation of thestiles from the rails. It will likewise be evident that when the top andbottom rails 12 of the edg` ing frame are assembled with the u per andlower ends of the core frame by slid gaging the dovetail ribs 15 in thedovetail grooves 9 and 16 in the rails 5 and stiles 4 respectively, ofthe core frame, there is effected an interlocking of the top and bottomrails of the edging frame with the upper and lower ends of the coreframe and likewise a locking of the top and bottom rails 5 of the coreframe against vertical longitudinal displacement between the stiles ofsaid frame. 1t will also be evident from the foregoing that when thestiles 11 of the edging frame are assembled with the stiles 4 of thecore frame and with the ends of the rails l2 of the edging frame by aslidable engagement of the tongues 13 of the stiles 11 in the dovetailgrooves 8 of the stiles 4 of the core frame, there will be not only aninterlocking of the stiles of the edging frame with the stiles of thecore frame, but likewise a locking of the ends of the top and bottomrails 5 and 15 of the core and edging frames with vthe stiles 11 `of theedging frame and, when all of the frame vsections are assembled in themanner stated, there can be no relative separation or displacement ofany of the sections except when one or the other of the stiles 11 of theedging frame is removed, so that, when the frame members are assembled,as stated, and these two stiles are in place, there is produced anexceptionally substantial and durable frame structure the parts of whichare so interlocked as topreclude any relative displacement ordisarrangement thereof.

The two panels 3 are of identical construction and each of these panelsis preferably of three-ply structure, comprising outer and inner pliesindicated respectively by the numerals 2O and 21, and an intermediateply 22. These pliesl are facially united to one another by adhesive andthe plies 2U and 21 are so arranged that the grain thereof will extendin the same direction and preferably vertically of the panel or in otherwords vertically of the door in its entirety. The grain of theintermediate ply 22 runs at right angles to the grain of the plies 20and 21 or in other words transversely of the panel or door and, in thismanner, warping of the panel plies is eifectually prevented.

By reference to Figures 4, 5 and 6 of the drawings itwill be observedthat the outer ply 20 of each panel is of greater marginal dimensionsthan the inner ply 21 and that the intermediate ply 22 is of lessdimensions than the ply 21, so that the ply 20 projects marginallybeyond the ply 21 and the ply 22 is marginally spaced inwardly withrespect to the plles 20 and 21 thus providing, in the panel, as a whole,projecting marginal portions 23 and 24, upon the plies 2() and 21 re.-spectively. The panels are assembled with the body frame structure ofthe door after the component parts of the core frame and the edgingframe have been assembled, with the exception of one of the stiles 11 ofthe edging frame. Th; panels are slidably fitted to the frame structurewith the upper and lower projecting marginal portions 23 of the ply 20of each panel slidably contacting the outer faces of the rails of theedging frame and the upper and lower project-lng marginal portions o theply 21 of each panel slidably fitting in the grooves 1S in the. upperand lower rails of the said edging frame, and after the panels have beenthus assembled with the frame structure, the frame stile 11, abovespecifically referred to, is slidably adjusted into place. Thiscompletes the door structure, and in order that all of the assembledparts may be mutually united, it is preferable that an 4adhesive coatfngbe applied to the contacting surfaces of the component parts of thestructure, where they interfit or interlock. It will be observed byreference to Figure 14 of the drawings that when the panels areassembled with the frame structure of the door, the lower corners of theplies 21 of the panels will register with the upper edges of theprojecting lug portions 19 of the top and bottom rails 12 of the edgingframe, these tongues therefore projecting into the grooves 14 formed inthe stiles 11 of the edgng frame.

From the foregoing description of the invention it will be evident thata door, constructed in accordance with the invention, may bemanufactured at a great economy in material and labor and in less timethan the ordinary constructions of doors of this type. It willfurthermore be' evident that due to the peculiar arrangement of thecomponent members of the core and edging frames and the peculiar mannerin which these frames are interlocln-d and mutuallv1 connectedr` bothas: regards their component members and likewise with respect to eachother, an exceptionally strong and durable 'traine strut#n ture is proYided to constitute the bodyY ot the door. and as this structure is otopen 'trame-like i'orin, the door will be hollow and thereforesubstantiallv soundproo't`. fit the same time the door is saitiirientlysubstantial and durable to etl'ertuallv serve its purpose and at thesame time is not subject to warping or ang.' tl to other distortion dueeimer Ishock orto changes` in weather conditions.

it will be evident from the foregoing description of the invention thatthe core trame l is of greater mass than the edging trame 2 andconstitutes, in eit'ect, the body ot the door, the panels 2S providingl'inished faces ior the door, and the edging trame constituting notonli1 a linislied edging for the door as a whole, but likewise,coacting` with the core trame and panels to enhance the rigidit)v anddurability o't the structure as a whole.

lt will be understood ot course that the door, embodving'the invention,maiv be constructed of wood, metal, a composition ot material, or anvcombination of dili'erent materials.

Having thus described the invention, what l claim is:

l. In a door of the class described, a core trame. an edgingI frame, thesaid trames each comprising members having interlocking parts Vtorholding the same assembled to form the respective trame, and certain ofthe meinbers ot the two frames having interlocking parts for holding theframes mutually assembled, and panels extending` over the opposite.sides of the assembled trames and having interlocking engagement withone of said trames.

2. ln a door of the class described, a core Ylli-ame, an edging trame,the said trames each comprising members having interlocking parts forholding the same assembled to form the respective trame, and certain o'tthe members or" the two trames having interlocking parts 'for holdingthe trames mutuallj,7 assembled, and panels extending over the oppositesides of the assembled trames and having interlocking connection withthe edging traine.

ln a door ot the class described, a core frame, an edging Yframe, theedging iti-aine being assembled abouty the core trame. the said frameseach comprising members having interlocking parts for holding the sameassembled to torni the respective traine, and corresponding members ofthe two frames having mutuallvv interlocking parts tor holding thetrames mutually assembled. and panels extending over the opposite sidesot the assembled frames and having interlocking engagement with themembers oE the edging trame.

yl. ln a door ot the class described, a core traine comprisine` 'tramemembers having interlocking parts ror holding` the membersl assembled to'torni the said it'rame, an edging frame including members correspondingto the members ot' the core 'traine and assembled about the core i'rame,corresponding members ot the core and edging trames having intertittingrib and groove connection with each other whereby to maintain the tramesmutuall)v assen'ibled, and panels extendingl over the opposite sides otthe assembled trames, and having marginal interlocking engagement withthe memb rs oit the edging traine.

ln a door ol the class described, a core irame, an edging trame, thesaid trames each comprising members having interlocking parts forholding the saine assembled to l'orm the respective trame, and certainot the members ot the two trames having interlocking parts ior holding`the trames mutualliy assembled, the members ot the edging irame havinggrooves in their inner sides extending parallel to their outer faces,and panels extending over the opposite sides o the assembled iframes andetl multiply construction and having projecting edge portions: of oneptyY litting into interlocking en gagement in the said grooves ot theedging trame wherebyv to mutually interlock the panels and the meinl ersot the edging trame.

t3. In a door or the class described, a core trame, an edging frame, thesaid frames each comprising members having interlocking parts forholdingl the same assembled to torni the respective trame, the edgingtrame being assembled about the core trame, certain ot' the members ofthe two frames having interlocking parts tor holding the frames mutuallyassembled, the members ot the core frame being of a width less than thecorresponding` members ot the edging frame. the members ot the edgingtrame being provided in their inner sides with longitudii'ialiyextending grooves, the grooves being located in the portions o'l themembers ot' the edging 'trame which project bevond the side laces of thecorresponding members ot the core iframe` and a n'iultiply panelextending over each side ot the assembled frame structure. each panelhaving its outermost plv provided with projei'ftino marginal portionsextending over the outer taces of the members of the edging traine andanother ot the plies ot the panel having projecting marginal portionsseating in the grooves in the meinw bers of the said edging trame.

't'. ln, a door of the class described. a core trame comprising stilesand top and bottom rails the stiles having dovetail grooves in theirinner and outer sides. the said rails having grooves in their upper andander sides res ectively and being rovided at their ends wit i tenonsfitting in t e grooves in the inner sides of the stiles, whereby themembers of the core frame are mutually interlocked and held in assembledrelation, an edging frame surrounding the core frame and com- 'prisingYstiles having dovetail ribs upon their inner sides interfitting in thedovetail grooves in the outer sides of the Stiles of the core frame, thesaid edging frame further comprising upper and lower railsv provided.upon their upper and under Sides respectively With dovetail ribs havinginterfitting engagement in the grooves in the upper and under sides ofthe top and bottom rails of the core frame, the ends of the rails of theedging frame being provided with dovetail notches to accommodate therespective ends of the dovetail ribs of the Stiles of said edging frame,and panels extending over the opposite sides of the assembled frames.

8. In a door of the class described, a core frame comprising Stiles andtop and bottom rails, the Stiles having dovetail grooves in their innerand outer sides, the said rails having grooves in their upper and undersides respectively and being provided at their ends with tenons fittingin the grooves in the inner sides of the Stiles, whereby the members ofthe core frame are mutually interlocked and held in assembled relation,an edging frame Surrounding the core frame and comprising Stiles havingdovetail ribs upon their inner sides intertitting in the dovetailgrooves in the outer sides of` the Stiles of the core frame, the saidedging frame further comprising upper and lower rails provided upontheir upper and under sides respectively with dovetail ribs havinginterftting engagement in the grooves in the upper and under sides ofthe top and bottom rails of the core frame, the ends of the rails of theedging frame being provided with dovetail notches to accommodate therespective ends of the dovetail ribs of the Stiles of said edging frame,and panels extending over the opposite sides of the assembled frames,the Stiles and rails of the edgingframe having longitudinally eX-tending grooves in their inner sides, and said panels being of multiplystructure and having projecting marginal ply portions havinginterfitting engagement in said grooves.

9. In a door of .the class described, a core frame comprising Stiles andtop and bottom rails, the Stiles having dovetail grooves in their innerand outer sides, the said rails having grooves inl their upper and underSides respectively and being provided at their ends with tenons fittingin the grooves in the inner sides of the Stiles, whereby the members ofthe core frame are mutually interlocked and held in assembled relation,an edging frame surrounding the core frame and comprising the stileshaving dovetail ribs upon their inner sides intel-fitting in thedovetail grooves in the outer sides of the Stiles of the core frame, thesaid edging frame further comprising upper and lower rails provided upontheir upper and under sides respectively with dovetail ribs havinginterfitting engagement in. the grooves in the upper and under sides olthe top and bottom rails of the core frame, the ends oi the rails of theedging frame being provided With dovetail notches to accommodate therespective ends of the dovetail ribs of the stiles of said edging frame,and panels extending over the opposite sides of the assembled frames,the Stiles and rails of the edging frame having longitudinally eX-tending grooves in their inner Sides, and said panels being of multiplystructure and having projecting marginal ply portions having interttingengagement in said grooves, each panel having projecting marginalportions f its outermost ply extendin over the outer faces ofthe Stilesand rai s of the edging frame at the corresponding side of the frame"structure.

l0. In a door of `the class described, a core frame, an edging frame,the said frames each comprising members having interlocking parts forholding the same as- Sembled to form the respective frame, certain ofthe members of the tWo frames hav ing interlocking parts for holding theframes mutually assembled, the members of the edging frame beingprovided in their inner sides with longitudinally extending grooves, themembers of the core frame being of less width than the correspondingmembers of the edging frame and said grooves in the members of theedging frame being located in planes beside the faces of the members ofthe core frame, opposite ones of the members of the edging frame havingprojecting tongues located in the planes of the grooves, andpanelsextending over the opposite sides of the assembled frames, the panelsbeing of multiply form, the margins of the outer pliesextending over theouter faces of the members of the edging frame andthe margins of aninner one of the lies of each panel fitting in the grooves in t emembers of the edging frame, the said lugs at the said ends of the saidopposite members of the edging frame constituting eontinuations of theopposite marginal portions of the last mentioned plies ofthe panels.

1l. In a door of the class described, a core frame comprising Stiles andtop, intermediate and bottom rails, the Stiles having dovetail groovesin their inner and outer sides, the top and bottom rails having groovesin their upper and under sides respectively and all of the rails beingprovided at their ends with tenons fitting in having grooves in theupper und under sides of the top and bottom rails of the core frame, theends of the rails ol the edging frame heiligl provided with dovetuilnotches to aeeonimodate the respective ends of the dovetuil ribs of thestiles of said edging traine. and panels extending over the oppositesides of the assembled frames.

In testimony whereoi I uflix my signuture.

FRANK VICTOR.

